Furniture forming systems



Jan. 3, 1967 M. A. MARSHAK 3,295,292

FURNITURE FORM I NG SYSTEMS Filed May 1s, 1963 2 sheets-sheet 1 Jan. 3, 1967 M. A. MARSHAK 3,295,292

FURNITURE FORMING SYSTEMS Filed May l5, 1965 2 SheetsSheet 3 QTTOR/VEY United States Patent O 3,295,292 FURNITURE FRMING SYSTEMS Martin A. Marshalt, Searingtown, NSY. (lill-12 84th St., Gaone Park, Long Island, NSY. 11101) Filled May 13, 1963, Ser. No. 279,783 9 Claims. ttl. 53-37) The present invention relates .to a furniture forming `system and it particularly relates to a method of forming furniture structures such as the backs and seats of furniture systems.

lIt is among .the objects of the present invention to provide a simple procedure for forming, for example, backs and seats of various types of furniture structures from plastic enclosures.

The sheet material may be readily formed into a bag and then inverted to receive the interior supporting structure.

Another object is to provide a novel furniture element assemblage structure in which it is not necessary to laboriously handle and turn the plastic covering elements and to stretch or pull the plastic covering element over the frame by means of skilled or trained labor.

Another object of the present invention is to provide a novel plastic molding operation in which unskilled labor may be utilized with ready positioning of a mold, with the mold forming the shape and size desirable and with the assembly taking place with a minimum of labor and a most economical high rate of product to produce a uniform and high quality product.

Still further .objects and advantages will appear in the more detailed description set forth below, it being understood, however, that this more detailed description is given by way of illustration and explanation only and not by way of limitation, since various changes therein may be -made by those skilled in the art without departing from the scope and spirit of the present invention.

In accomplishing the above objects, it has been found most satisfactory according to one embodiment of the present invention to form an interior mold which will approximate and closely conform to the shape of the final article Whether it is a seat or back which is to be formed.

This shape will be provided with a series of small openings extending along the corners thereof not over l/gg in diameter and desirably between 1&4 and 1/128 which will be tapered outwardly, and the entire form will then be enclosed in a vacuum chamber in which a vacuum of 15 to 32 mercury may be a-pplied.

Desirably, the device may also be heated so as to render the sheet material which acts as a covering to be somewhat soft and pliable, a temperature being utilized ranging from 150 F. to 225 F.

The temperature, however, should always be kept at 50 to 75 F. below the melting or extreme softening point of the sheet plastic material.

Among the materials which may -be utilized are polyvinyl chloride, polyvinyl acetate, polyvinyl chloride-acetate, similar polyvinylidine compounds, polyethylene, polypropylene or nylon.

These materials should desirably be of a gauge of between to 16 gauge, and the preferred material is a vinyl chloride polymer having a molecular size of about 10,000 to 100,000 and which contains about to 25 of plasticizer such as dioctyl phthalate.

Desirably, a sheet of material and desirably a sheet of polyvinyl chloride plastic is stitched together so that its edges project and the edges are separated by a relatively stiff material desirably of extruded polyvinyl chloride or said other plastic `materials having about the same thickness or about twice the thickness of the sheet material with a bead which will be from three to four times the thickness of the sheet material.

These three sheets are desirably stitched or welded together and then the bag thus formed is inverted and placed over a mouth so as to be inverted and closely conformed to the interior of the mold structure when the vacuum is applied.

After the vacuum is applied `and the enclosure is in position, suitable inserts may be made either for a back or a seat.

Where a back is formed, the Wood struct-ure is inserted and the ends are then stapled into position onto the edge of the frame.

Where a seat is formed, a suitable shape may be inserted conforming to the seat face with suitable foam or batting being inserted thereinto.

In either case, the interior shape of the mold will oonform to the shape of the subject which is to be formed.

In one preferred form of the invention, the interior shape of the m-old is sufliciently larger than the shape to be formed so that the material is stretched and when the vacuum is released, the plastic material will contract back onto the shape inserted therein to conform thereto.

With the foregoing and other objects in view, the invention consists of the novel construction, combination and arrangement of parts as hereinafter more specifically described and illustrated in the accompanying drawings, wherein is shown an embodiment of the invention, but it is to be understood that changes, variations and modifications can -be restorted to which fall within the scope of the claims hereunto appended.

In the drawings wherein like `reference characters denote corresponding parts throughout the several views:

FIG. l is an exploded view showing the various elements of the structure and the manner in which -they are assembled together.

FIG. 1a is a transverse sectional view upon the line 1--1 of FIG. 1 showing the method of forming the bag.

FIG. lb is a fragmentary transverse sectional view indicating the location of the suction openings along the corner of the vacuum cavity.

FIG. 2 is a transverse sectional view of the mold indicating the manner in which the assembly is made upon the line 2--2 of FIGS. 1 and 3 and upon a larger scale as compared to FIG. 1.

FIG. 3 is a section of the mold upon t-he lines 3 3 of FIGS. l and 2 and upon a larger scale as compared to FIG. 1.

FIG. 4 is a nal view of the article of furniture as formed in the mold structure of FIGS. 2 and 3.

FIG. 5 is a transverse vertical sectional View showing a mold structure -for forming a seat of a chair.

FIG. 6 is a vertical sectional view showing alternative method of forming a chair seat.

FIG. 7 is a transverse sectional view of a corner showing the manner in which the corner is drawn into the edge of the mold by the vacuum applied upon an enlarged scale as compared to FIG. 5.

FIG. 8 is a fragmentary transverse sectional view upon the line 3 3 of FIG. 7.

Referring to FIGS. 1 to 3J there is shown a mold A, an outer vacuum housing B, an inverted bag structure C, and an insert D to form the final furniture article E.

The actual molding structure A consists of a deep cavity having the inside and outside walls 10 and 11 to conform to the shape of the sides of the article with the end walls 12 conforming to the side edges of the article.

The top of the device has a cover plate 13 which is below the top mouth 14 onto which the lower edge 15 of the inverted bag C is to be fitted.

The cover plate 13 is to be fitted upon the ledge 16 held in position by the screws 17 in the vacuum chamber B.

The side walls of the vacuum chamber 18 and 19 and the end walls 20 as well as the bottom wall 21 are of sufficient strength as to withstand vacuum pressure and desirably the lower end of the vacuum chamber is reinforced by a plate 22 held in position by the screws 23 which in turn will act Ias a mouth for the connecti-on 24 to the vacuum pump or other vacuum source.

This vacuum connection 24 is held in position by means of the flange 25 having the screws 26 into the support plate 22.

The main mold chamber itself has lower inside and outside edges 35 and 36 as well as its side edges 37 and 38, and they are provided with la series of small openings 39 of capillary size and desirably not exceeding 1/64" in diameter which may are outwardly so as to permit the vacuum established in the chamber F to :be communicated into the interior space of the form A and cause the bag C to be drawn down into the recess as best shown in FIGS. 2 `and 3.

The vacuum chamber preferably has a reinforcing plate 40 at the base thereof held in position by the screws 41 and 42 in which case the openings will be positioned across the corners 37 and 38 to draw the inverted polyethylene or polypropylene bag thereinto.

The mouth portion 14 is desirably provided with a Toughened or adhesive facing as indicated at 43 so that the lower mouth portion 15 of the inverted bag C will closely conform thereto before it is drawn inwardly by the vacuum.

Desirably the cover 13 Will =be held open as at 15 by means of the vacuum although if desired a gasket 44 may be employed to assure a tight seal when the vacuum is applied.

The inverted bag as indicated in FIGS. 2 and 3 will then have the interior frame D readily inserted therein whether it be a seat frame or a back frame.

The back iframe may consist of a wooden structure having the side members 45, and the base member 46 with the top member 47 and the interior filling 4S.

This :structure will be inserted when the vacuum is on and upon release of the vacuum at the connection 24, the plastic material C in stretch condition may then be released and will tightly cling to the sides and bottom of the frame structure D to form the structure as indicated in FIG. 4.

The mouth portion 15 may then be released from the adhesive or holder material 43, turned inwardly as indicated at G in FIG. 4 and stapled in position as indicated by the :staples 49 to form the completed article of furniture.

It will be noted that the bag is formed as indicated in FIG. 1a by rst stitching together the edges 50 against the tail 51 on the inside of the portion 52.

The section of FIG. 1a indicates when the bag is inverted as indicated at C in FIG. 1.

When the bag is then drawn into the recess formed by the mold A, the portion 52 will project youtwardly as indicated at H in FIG. 4.

Desirably the ysize of the inverted mold is always at least 10 to 20% wider or greater spaced than the final article so that the plastic cover C will be stretched and then contracted back onto the form D when the pressure is released.

In this manner, the accurate lit of the plastic enclosure is obtained upon the base structure.

'Ihe most ysatisfactory seal at 43 is desirable.

In the processing of the bag or cover, desirably the front and back are stitched together from two sheets or polyethylene, polypropylene or Vinyl chloride of l to 16 gauge leaving the bottom edge open.

If desired, this polyethylene may be laminated with a Woven or knit cloth or it may consist of an impregnated knit cloth such as the fabric known as Osanberg.

Before the vacuum is released, it is also possible to blow into the inverted bag a foam or other softening material in finely divided form including cotton batting.

If desired, foam inserted may be placed therein.

Where a great structure is to be produced, a suitable form is inserted which will give the desired curvature of the seat structure.

By using the applicants invention, it is not necessary to -turn the plastic inside 4out by hand and then place it upon a mechanism separating device.

The frame or interior structure may be readily inserted in the applicants arrangement and need not be laboriously fitted to the interior structure.

`Once the plastic has been conformed to the exterior shape of the interior frame or filling, it is not necessary to reheat the plastic or to pull or stretch it by hand or to use skilled labor in shaping it.

In the applicants arrangement above, the plastic cover is merely stretched over the mouth of the mold and is automatically inverted when the vacuum is turned on.

The wooden frame is then wrapped with cotton batting or enclosed between sheets of cardboard, and the plastic when released by the vacuum will automatically conform itself to the inserted shape with the free end being readily stapled or adhesively connected in position.

As shown in FIG. 1b, the corners are provided with the openings 60 which are flared outwardly, and these openings may either be directly at a corner or on each side of a corner so that the protective material 61 is drawn directly up to such corner by the high vacuum applied.

These openings may be spaced 1A; to 1A apart, and they are desirably 4arranged along all of the edges 63 and 64 of the shape that is to be formed.

Some of them may also be positioned at locations located at 65 and 66 along the side facings of the shape that is to be formed although this is not necessary.

The applicant, has provided a most economical device for forming plastic covered furniture backs and seats with uniformity and at low cost and without requiring skilled labor and considerable wood in fitting each plastic cover to the furniture structure therebelow.

Referring to FIG. 5, there is shown an enclosure having the base 101 and the side walls 102. The vacuum is applied through a central conduit 103 which projects through the base Wall 101 and the seal thereto is indicated at 104.

The wooden base or plaque 105 is supported on the b'ottom wall by the spaces 106. The seat cover 107 may be applied over the outside faces 108 of the Wall 102 with its edges as indicated 109 projecting downwardly over the outside faces 108. A Vacuum is then applied by suitable means to the conduit 103 which will create a substantial vacuum by drawing air downwardly as indicated by the arrows 110, inverting and stretching the seat cover so that its bottom face 111 will be drawn down against the top face 112 of the board 105, and so that the corner beading 121 will be drawn inwardly and downwardly against the outer edges of the board 105. This is best shown in FIGS. 7 and 8 where the board 105 is shown as being very narrowly spaced at 122 from the inside face of the wall 102 and has the narrow space slots 127 which will assure that there will be suiiicient vacuum to draw down the plastic material so as to conform to the interior shape of the form 100.

It will be noted that the wall 113 will be drawn downwardly against the inside face 114 of the wall 102 whereas the top of the seat as indicated 111, is drawn down against the top face 112 of the board 105. The beading 121 will have a projecting circular portion 123 which is stitched at 124 to the inturned flaps 125 and 126 of the edge construction.

After the bottom and sides 113 of the plastic seat cover have been drawn into the cavity on top of the board 105 by the vacuum, the layers of batting 12S may be placed in position one on top of the -other to fill the space and the finishing board 129 may be placed in position. This board has a center opening 130 to permit escape of air and when it has been placed down in position, the edges 109 may be turned inwardly and stapled in position on the top face of the board 129.

In the alternative arrangement of FIG. 6, the enclosure or container 150` of metal has a vacuum or suction connection 151 and has a board 152 supported by the bracers or spacers 153 to hold it in position. The spacers 153 may be screwed, riveted or nailed or otherwise attached to bolt the board 152 and the base 150.

In the embodiment of FIG. 6, the inverted seat bottom 154 is drawn down by vacuum application so that its edge headings 155 will be drawn into the corners 156 by the vacuum applied to the edge slots as indicated by the arrows 157.

In the embodiment of FIG. 6, the layers of batting 128 are not utilized but the end board 158 is `applied on the end of the tube 159 against the stop 160 and it will then be inserted inside of the outer portion 161 of the collapsed inverted plastic seat enclosure.

Linters or fibers are then blown in as indicated by the arrow 162 into the space 163 until such space is filled with such linters and then the tube with the stop collar 160 may be Withdrawn leaving the board 158 in position.

This may be accomplished after stapling the inturned edges 164 of the seat enclosure in position.

To prevent any escape of linters a peripheral netting 165 may be stitched as indicated at 166 to the periphery of the plastic material 164 and drawn together by means of a tie or drawstring 166 which can fit int-o or pass through a tubular enclosure 167.

When the seat is finished the opening 168 will be left therein and this may be covered by a screen or net as lthe case may be, to prevent the escape of any loose linters or fibers 163. The netting 165 may then be cut away to give the finished seat construction.

As many changes could be made in the above furniture forming systems, and many widely different embodi ments of this invention could be made without departing from lthe scope of the claims, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.

There is suicient space left around the edge of the board 158 to permit escape of air and the screening 165 may cover any gap between the board or plaque 158 and the inside face of the side wall 161.

The gauge may widely vary and need not be in the range of to 16.

Instead of the screening 165 it is also possible to use a plastic perforated or properly shaped screen enclosure fitting around board 158 to permit escape of air as board 158 is gradually forced into the enclosure walls 161 and the plastic side enclosure.

Having now particularly described and ascertained the nature of the invention, and in what manner the same is to be performed, what is claimed is:

1. A method of forming furniture seats `and backs provided with plastic covers, which includes providing a form corresponding in shape but larger than the article to be formed, placing an inverted plastic bag having an open mouth and closed bottom and side edges into the mouth of said form, said bag corresponding to said cover in said form, applying a vacuum to the exterior of said form to cause inversion of the plastic cover to proper shape thereinto, stretching and drawing the inverted bag into said form so that the sides and bottom of the bag are inverted, due to the force of said vacuum and said vacuum drawing the sides and bottom of said bag after inversion against the sides and bottom of said form filling the inverted bag, releasing the vacuum and then closing the open mouth thereof.

2. A method of forming furniture seats and backs provided with plastic covers, which includes providing a form corresponding in shape but larger than the article to be formed, placing an inverted plastic bag having an open mouth and closed bottom and side edges into the mouth of said form, said bag corresponding to said cover in said form, applying a vacuum to the exterior of said form to cause inversion of the plastic cover to proper shape thereinto, stretching and drawing the inverted bag into said form so that the sides and bottom of the bag are inverted, due to the force of said vacuum and said vacuum drawing the sides and bottom of said bag after inversion against the sides and bottom of said form filling the inverted bag, releasing the vacuum and then closing the open mouth thereof, said bag being stretched so that it will contract back onto the filling applied in the inverted cover.

3. A method of forming furniture seats and backs provided with plastic covers, which includes providing a form corresponding in shape but larger than the article to be formed, placing an inverted plastic bag having an open mouth and closed bottom and side edges into the mouth of said form, said bag corresponding to said cover in said form, applying a vacuum to the exterior of said form to cause inversion of the plastic cover to proper shape thereinto, stretching and drawing the inverted bag into said form so that the sides and bottom of the bag are inverted, due to the force of said vacuum and said vacuum drawing the sides and bottom of said bag after inversion against the sides and bottom of said form filling the inverted bag, releasing the vacuum and then closing the open mouth thereof, said bag being formed of strips of polyvinyl plastic sheet material of 10 to 16 gauge the edges of which have been stitched together with a separating padding, said padding being first inverted and then projecting on the vinyl cover.

4. A method of forming furniture seats and back provided with plastic covers, which includes providing a form corresponding in shape but larger than the article to be formed, placing an inverted plastic bag having an open mouth and closed bottom and side edges into the mouth of said form, said bag corresponding to said cover in said form, applying a vacuum to the exterior of said form to cause inversion of the plastic cover to proper shape thereinto, stretching and drawing the inverted bag into said form so that the sides and bottom of the bag are inverted, due to the force of said vacuum and said vacuum drawing the sides and bottom of said bag after inversion against the sides and bottom of said form filling the inverted bag, releasing the vacuum and then closing the open mouth thereof, said vacuum being applied along the edges of the seat and back so as to cause said edges to conform to the shape.

5. A furniture manufacturing system, particularly for curved seats and backs for light weight chairs which comprises an inside deep shell of a light weight metal having wide curved front and back narrow sides, an open top and a closed bottom and an outstanding attachment flange a short distance below the outer mouth thereof, a deep outer vacuum chamber larger than the shell having closed sides and bottom, said flange and shell acting as a cover for said chamber and the flange being mounted in and on said open top of said chamber.

6. The system of claim 5, said top having a sleeve member to engage the bottom of an inverted form corresponding to the outside of said seat or back and said shell having a plurality of small openings along the lower corners adjacent the junctions of the sides and bottom through which vacuum is applied to the shell from the chamber to draw said inverted form into said shell to cling to the sides and bottom thereof.

l 7. The system of claim 5, said top having a sleeve member to engage the bottom of an inverted form corresponding to the outside of said seat or back and said shell having a plurality of small openings along the lower corners adjacent the junctions of the sides and bottom through which vacuum is applied to the shell from the chamber to draw said inverted form into said shell to cling to the sides and bottom thereof and an insert consisting of a curved member to conform to the interior of said inverted form to t inside and hold said form eX- panded after the vacuum has been released.

8. The system of claim 5, the vacuum application to the chamber being achieved by an opening directly through the bottom of the chamber directly under the shell When the shell is mounted in the chamber.

9. The system of claim S, said top having a sleeve member to engage the bottom of an inverted form corresponding to the outside of said seat or bag and said shell having a plurality of small openings along the lower corners adjacent the junctions of the sides and bottom through which vacuum is applied to the shell from the chamber to draw said inverted form into said shell to cling to the sides and bottom thereof and said form having seams along the -rniddle of the narrow sides and bottom thereof and a seam filler member having a covering cylindrical ridge extending along the seam.

References Cited by the Examiner UNITED STATES PATENTS 1,465,200 8/1923 Yates 223-43 2,418,142 4/1947 Socke 53-386 2,604,244- 7/1952 Tripp 53-386 2,831,510 4/1958 Carter 53--386 X FRANK E. BAILEY, Prmafy Examiner.

P. H. POHL, Assistant Examiner. 

1. A METHOD OF FORMING FURNITURE SEATS AND BACKS PROVIDED WITH PLASTIC COVERS, WHICH INCLUDES PROVIDING A FORM CORRESPONDING IN SHAPE BUT LARGER THAN THE ARTICLE TO BE FORMED, PLACING AN INVERTED PLASTIC BAG HAVING AN OPEN MOUTH AND CLOSED BOTTOM AND SIDE EDGES INTO THE MOUTH OF SAID FORM, SAID BAG CORRESPONDING TO SAID COVER IN SAID FORM, APPLYING A VACUUM TO THE EXTERIOR OF SAID FORM TO CAUSE INVERSION OF THE PLASTIC COVER TO PROPER SHAPE THEREINTO, STRETCHING AND DRAWING THE INVERTED BAG INTO SAID FORM SO THAT THE SIDES AND BOTTOM OF THE BAG ARE INVERTED, DUE TO THE FORCE OF SAID VACUUM AND SAID VACUUM DRAWING THE SIDES AND BOTTOM OF SAID BAG AFTER INVERSION AGAINST THE SIDES AND BOTTOM OF SAID FORM FILLING THE INVERTED BAG, RELEASING THE VACUUM AND THEN CLOSING THE OPEN MOUTH THEREOF. 